Die and method of making same



H. PHILLIPS ET AL 3,063,349

DIE AND METHOD MAKING SAME Nov. 13, 1962 2 Sheets-Sheet 1 Filed Sept.27, 1960 FIG 7 K) J|\ A-k/ 1 Q L Ff FT 1 A J-k i I T I A; I

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HARP) L. PH/LL/PS LYTTON S. FA/N WWW H. L. PHILLIPS ET AL 3,063,349

DIE AND METHOD OF MAKING SAME Nov. 13, 1962 Filed Sept. 27, 1960 2Sheets-Sheet 2 INVENTOR5. HARRY L. PH/LL/PS LYTTON s. FA/N BY W I WX' nTI'ORN/EVS 3,63,349 Patented Nov. 13, 1952 ice This invention is acontinuation in part of copending application Serial No. 9,545 filedFebruary 18, 1960, and relates to a die for cutting blanks from sheetmaterial.

' One of the objects of the invention is the provision of a die of theflat bed type in which the rules are adapted to be removed and replacedafter the die is locked in the chase and has been used or has beenreadied for use, without disturbing the positions of the other rulesrelative to each other and which rules, when so replaced, arefrictionally held rigid relative to the other rules and to the case.

Another object of the invention is the provision of a die for cuttingand creasing carton blanks from a sheet of cardboard, which die includessteel cutting and creasing rules that are frictionally held in cuttingand creasing positions against movement relative to each otherirrespective of whether the die is held in a press with the cutting andcreasing edges directed upwardly or downwardly, and irrespective of thesize of the die or the number of rules, and in which die any of therules may be removed and replaced by others that will be frictionallyheld rigid in precisely the same positions as those that were removed.

Another object of the invention is the provision of a main die that ismade up of a plurality of sub-dies, each including cutting rules, orcutting and creasing rules that are adapted to simultaneously formblanks from a sheet of material, such for example, as cardboard, andwhich rules may be withdrawn from any one or several of the sub-dies andreplaced, without displacing or changing" the positions of, or looseningany of the other rules in any of the sub-dies.

A still further object of the invention is the provision of a main diehaving rules adapted to simultaneously form a plurality of correspondingblanks and which rules are releasably and rigidly held together in aplurality of groups, each group relating to one of the blanks adapted tobe formed, and each group being releasably held as a unit relative tothe other groups, and which groups releasably support other blankcutting rules between them that are adapted to cut along lines common toadjacent blanks.

An additional object is the provision of a method of making a single diethat is adapted to simultaneously form a plurality of blanks that areidentical to each other, and in which die predetermined multiples of therules may be changed as a unit, and also in which die individual rulesof any of the said multiples may be replaced without changing therelative positions between the other rules or between the replaced rulesand the others.

In explanation of the foregoing, in the carton making industry, as anexample, the dies employed for making blanks in which a very high degreeof accuracy is required, are flat bed dies, or dies adapted to be usedonly on flat-bed presses, and each die is adapted to cut and to crease aplurality of carton blanks of corresponding shape and size. Theconventional Miehle and Mercury presses are examples of several types ofpresses using flat bed dies.

Thus, it may be said that each die is a main die made up of a pluralityof sub-dies, each sub-die being adapted to cut and to crease a cartonblank. One of such main dies may be called a IO-on die where it isadapted to form ten carton blanks. Usually the smaller the size ofcarton blanks to be cut the greater the number of subdies, and thelarger the size of the carton blanks, the smaller the number ofsub-dies. The capacity of the press or the number of blanks to be cutmay determine the size of the main die. A 10-on die will be referred tohereinafter merely as a definite example of one of such main dies.

The conventional method practiced for many years in making a 10-on diehas been to cut wooden pieces, one at a time, to shapes that willsupport, between adjacent pairs thereof, the rules of the die when thewooden pieces and the rules are locked in a conventional chase. Sincethere are ten sub-dies in a 10-on die, each of which is intended to cutand to crease a blank that is substantially the same as the other nineblanks, it is obvious that many of the wooden pieces that are cut forthe difierent subdies should be of exactly the same size and contour.However, this is not true, since it is not humanly possible for aworkman to separately cut pieces that will be identi cal, and when themany sub-dies are placed in a chase in rule supporting positions and thechase is tightened against the pieces to draw them into tight engagementwith the rules, the variations in the wooden pieces and in the shapes ofthe rules that have been separately and individually cut and bentusually makes necessary a long and costly lock-up period. During thisperiod the workmen must use shims and other means to rectify thevariations so that the rules will come within certain permissibletolerances. This lock-up period or time may take as long as severaldays.

In actual practice, some rules in a main die usually require replacementfrom time to time. In a conventional wooden fixture die, as abovedescribed, the chase must be loosened in order to etfect thereplacement. Once the chase is loosened, the adjustment originally madeto insure the correct cutting and creasing of the blanks is no longermaintained, and the lengthy lock-up time must be repeated. In someinstances this time may also extend to a day and more.

Also, heretofore, when a run of blanks has been finished, but there islikelihood of more being ordered within the reasonably near future, thechase including the wooden fixture dies remains locked in order to avoidor reduce the necessity for the costly lock up time. The chase and diesare then stored away, with the result of tying up a fairly costly chaseand valuable storage space, to say nothing of the possibility of therules and wooden blocks being accidently displaced.

With the present invention, the original lock-up time is negligible,normally being substantially less than an hour, and rules may be changedin groups or singly, in substantially the same time without altering thepositions of the other rules or their supports, and usually withoutloosening the chase where only individual rules are replaced. When a runof blanks is completed, the subdies can be quickly removed and stored ina compact space and the chase used for other dies since the lock-up timein replacing the sub-dies and rules is negligible.

Other objects and advantages will appear in the description and in thedrawings.

In the drawings,

FIG. 1 is a top plan view of a 10-on die in a chase.

FIG. 2 is a bottom plan view of one of the ten subdies of FIG. 1.

FIG. 3 is a cross sectional view taken along line 33 of FIG. 2.

In detail, in FIG. 1 the rigid chase is generally designated 1, andincludes four side members.

Disposed within the chase and on a flat bed is the rectangular 10-011die, generally designated 2.. Each of the,

ten sub-dies forming the main die 2 is generally designated 3. FIG. 2shows one of such sub-dies in a bottom plan view.

Between two of the adjacent rigid sides of the rectangular chase 1 aremovable rails 4, 5 that are parallel with the sides of the chaseadjacent respectively thereto, and the IO-on die is disposed betweensaid rails and the other two rigid adjacent sides of the chase.Conventional quoins 6 disposed between the movable rails 4, 5 and therigid sides of the chase that are parallel thereto. The quoins areadapted to tighten the rails against the die 2 for rigidly holding thedie in the chase and against the two rigid sides of the chase that areat the opposite sides of the die from the rails 4, 5. The chase, whichincludes the chase mem bers 1, rails 4, 5 and the quoins, isconventional.

The bed on which the chase and die are assembled is not part of thechase, the latter being the open frame between the sides of which thedie is locked.

Except for the rules, each sub-die 3 may be substantially a unitaryblock of an epoxy compound slotted to frictionally, but firmly, hold therules in their correct positions, substantially as described in saidcopending application. In the example illustrated in FIG. 2, the cuttingrules are indicated at 7 and the creasing rules at 8.

In forming the sub-die, the cutting and creasing rules are supportedalong hteir cutting and creasing edges in highly accurate positions, andwithin a rectangular frame having inner surfaces that are positionedwith extreme accuracy at right angles to each other. Certain of therules are formed with aligned recesses 9 opening outwardly of the baseedges thereof that are opposite to their cutting and creasing edges, andtie bars or dowels 10 are disposed in these aligned recesses, some ofthe tie rods crossing others as indicated in FIG. 2 and others, as at11, being relatively short. The arrangement is such that the epoxycompound that is to be poured into said frame and at opposite sides ofthe rules, will be rigidly connected by the tie bars to which the epoxycompound will bond or adhere. This compound will also fiow through therecesses 9' in which the rods 10 are positioned, and were the rodsomitted, the compound would fill the recesses 9. Thus it is seen thatthe compound at opposite sides of the rules is integrally connectedirrespective of the rules, but nevertheless reinforcing rods are usuallydesirable. The rules are coated with a parting wax and therefore theywill not adhere to the epoxy compound. Nor will the epoxy compoundadhere to the rectangular frame, since it also is coated with a partingwax.

After the compound is poured to substantially the level of the baseedges (but preferably slightly below said edges) and is cured, the frameor rails defining the outline of the sub-die may be removed and theepoxy compound and rules will form a sub-die, and the marginal portionsof the rules along their working edges will project from the epoxycompound exactly the desired distance. The use of the term working edgesrefers to the cutting or creasing edges or both.

In this sub-die, any of the rules may be withdrawn by use of a properinstrument such as a rule puller, but they so snugly fit the slotsformed in the epoxy compound that they will be rigidly held in placeduring all cutting and creasing operations in a press independently ofany pressure from the chase in which the sub-dies are locked.

FIG. 2 being a bottom plan view of a sub-die, the open ends of therecesses in the rules are indicated. The dowels or tie rods 10 are fullyenlosed within the epoxy compound as seen in FIG. 3.

Since the base edges of the rules, which are in full line in FIG. 2, arecoplanar, all pressure against the cutting and creasing edges of therules in a blank forming operation will be transmitted to the bedthrough the rules. The epoxy compound merely holds the rules rigidly intheir accurately arranged positions.

1 In the fabricating of the main die 2, the sub-dies 3 are positioned(in the example shown) in two rows of five each with the rows extendinglongitudinally of the chase. The group of ten sub-dies are positionedagainst two of the rigid adjacent sides of the chase, except for acutting rule 15 that is between one of said adjacent sides and a cuttingrule 16 that is against the other side of said adjacent sides. Opposedto and parallel with rule 15 is a second rule 15 disposed between theside chase rail 5 and the group of sub-dies, while a second rule 16 thatis opposed to and parallel with the rule 16, already described, isbetween the end chase rail 4 and the group of sub-dies.

The quoins 6 between the side chase rail 5 and the main chase side 1,and between end chase rail 4 and said chase end function to hold thesub-dies and the rules 15, 16, 17 and 18 tightly together, but nopressure from the operation of the quoins is transmitted to the rules 7,8 within the sub-dies.

Each of the sub-dies is in a position corresponding to that of theothers, and since the sub-dies are exactly rectangular and of exactlythe same size, it will be apparent that when the chase is locked aroundthe sub-dies, the rules 15, 16, 17 and 18 are the only rules thatreceive any pressure from the locking operation, and rules 15, 16 arefrictionally held between the chase and the sub-dies, while rules 17, 18are frictionally held between the sub-dies.

The sub-dies cannot possibly be misaligned nor can the rules in thesub-dies or the cutting rules 15-18 be misaligned during the locking ofthe chase and thereafter. Thus the heretofore existing problem ofadjusting the rules during the lock-up step has been eliminated.

Any of the rules 7, 8 may be withdrawn and replaced without altering thepositions of the other rules and without loosening the chase, since thebody of the die is not in separate movable pieces as in the case of thewooden fixture dies. The replaced rules are frictionally, but rigidly,held in exactly the same positions of the rules that were replaced. Thisfrictional fit is such that a die may be successfully re-ruled aninfinite number of times, and after many millions of cartonblanks havebeen cut by a die it has been impossible to discover any variationbetween the first and last of such blanks.

There are instances in which it may be found desirable to replace one ormore of the sub-dies as a unit. This can be readily accomplished byloosening the chase and replacing one or more entire sub-dies withoutdisturbing the positions of the other sub-dies and rules. After thesub-die or sub-dies are replaced and the chase is locked, the rules willbe in their exact desired positions.

As pointed out in said copending application, the accuracy of theoutlines of the plastic bodies of the subdies is essential to theforegoing results, and in said application, one method of making all ofthe sub-dies exactly alike is described in detail.

It should be noted here that the cutting rules 1518 do not necessarilyform the contours or outlines of the finished blanks, although in theparticular sub-dies illustrated, the rules 17 form two edges of eachblank that are common to adjacent pairs of the blanks at opposite sidesof said rule. The cutting rules 7 form the outlines of the other twoedges of each blank and the material between rules 7 and rules 17 may bestripped from the blanks, although the rules 17 define the maximumwidth.

From the foregoing explanation and drawings, it is seen that the workingedges of the rules, i.e., the cutting and creasing edges, are parallelto the base edges. The flat sides of the rules will be perpendicular tothe flat bed on which the base edges will be positioned. The outer edgesor sides of each sub-die is exactly at right angles to the bed thatsupports the rules, and they are exactly at right angles to each other.Each sub-die, being formed from a mold as described in said copendingapplication, is exactly of the same size as the others. The recesses inthe rules in which the tie rods are received open outwardly of the baseedges of the rules, hence each rule can be withdrawn from the workingside of the sub-die and a correspondingly recessed rule may besubstituted for the rule that has been withdrawn. No screws, clamps, orauxiliary means is required to firmly but releasably hold the rules inthe sub-dies, whether the working edges are directed upwardly ordownwardly.

The epoxy compound of each sub-die is unaffected by humidity or changesin temperature Within the range of temperatures encountered in actualworking conditions.

1 Hence there is no popping of dies, such as occurs in the case ofwooden fixture dies at relatively high atmospheric temperatures andrelatively high humidity.

The epoxy compound used is of approximately the weight of the plywoodused in the conventional wooden fixture dies, hence large sub-dies maybe used in a commercial operation free from objectionable weight.

Each sub-die may be described as being a rectangular block or slab ofplastic material having slots cast therein conforming to the linearcontours of the working edges of the rules for forming a blank, andwhich slots have a uniform width equal to the thickness of the ruleswhereby the rules are frictionally held thereon rigid relative to eachother. The widths of the slots is such that the rules are tightly heldin the slots.

The block or slab itself is of substantially uniform thickness that isequal to the major height of the rules, and steel rules are rigidly butreleasably held in said slots with their working edges spaced from oneside of said slab and with said base edges free from obstruction forseating along their entire lengths on the planar surface of a flatsupporting bed.

Each block or slab is formed of smaller blocks spaced from each other bythe slots and substantially integrally held together at spaced points bybridges or ties between the blocks extending across the slots. In someinstances some of the outside blocks in a slab may not necessarily betied to the others by rods, particularly where an intricate arrangementof rules may exist, but this does not alter the fact that each sub-dieis substantially a unit adapted to be handled as such.

' The method of forming the main die may be said to comprise the stepsof releasably holding a plurality of rigid rule carrying supportstogether by variable pressure applied thereto and frictionally holdingseparate blank forming rules between said supports by said pressure andfrictionally and releasably holding corresponding groups of blankforming rules in said supports, respectively, free from said pressureand free for independent removal of the rules in each group from othersin the same group without in any manner altering the degree of pressureapplied to said supports and to said separate blank forming rules.

The variable pressure mentioned comes from driving the quoins in thelock-up procedure, while a constant frictional resistance is maintainedbetween the sides of the rules and the sides of the slots in each slab.The rules between the supports are obviously subject to the pressurefrom the quoins as is applied to the supports.

Earlier note has been made that the lock-up time having been reducedfrom hours and sometimes days to a matter of minutes, there is nonecessity in the present instance for retaining the main die 2 in achase in order to save the lock-up time. Previously, many valuablechases, representing a considerable investment, had been stored with thesub-dies locked therein, because of the fact that any loosening of thechase would result in loosening all the rules and wooden fixtures sothat reassembly and readjusting of the dies would not be necessary. However, with the present invention the sub-dies can be removed and storedwithout altering the positions of the rules therein. The straight rules15, 16, 17 and 18 need no time for adjustment when replaced afterremoval, and the sub-dies can be repositioned in a chase in associationwith said rules -18 without the slightest adjustment being necessary.

It is to be understood that the claims appended hereto 6. are intendedto cover all changes and modifications of the example of the inventionherein chosen for the purposes of disclosure, which do not constitutedepartures from the spirit and scope of the invention.

We claim:

1. A die for forming a plurality of blanks from sheet materialcomprising: a plurality of separate corresponding groups of blankforming rules each group having working edges for engaging such sheetmaterial and exposed coplanar base edges opposite to said working edgesfor engagement wtih a common planar bed, separate rigid, unitary ruleholding means frictionally but releasably holding the rules in eachgroup together for removal of each group as a unit from the othergroups, and a chase enclosing said rule supporting means actuatable fortransmitting pressure to said rule supporting means for frictiona-llyholding said rule supporting means stationary .relative to each otherwithin said chase, said rule supporting means each including rigid meansthereon extending through the rules of the group frictionally heldtherein between the base and working edges of the rules of such groupfor transmitting said pressure across each of said rule supporting meansindependently of the rules of said groups whereby said rules may bewithdrawn from said rule supporting means for replacement thereof whilesaid rule supporting means are frictionally held in said chase bypressure from said chase, separate blank form'- ing rules between saidrule supporting means spacing and separating said rule supporting meansfrom each other thereby enabling removal of any of said rule supportingmeans including the group of rules held therein from the others of saidrule supporting means free from direct frictional engagement with therule supporting means adjacent thereto, said separate blank formingrules being frictionally held between said rule supporting means bypressure from said chase upon the latter being actuated to hold saidrule supporting means in said chase.

2. A die for forming a plurality of blanks from sheet materialcomprising: a plurality of separate corresponding groups of blankforming rules each group having Working edges for engaging such sheetmaterial and exposed coplanar base edges opposite to said working edgesfor engagement with a common planar bed, separate rigid, unitary ruleholding means frictionally but releasably holding the rules in eachgroup together for removal of each group as a unit from the othergroups, and a chase enclosing said rule supporting means actuatable fortrans mitting pressure to said rule supporting means for frictionallyholding said rule supporting means stationary relative to each otherwithin said chase, said rule sup-. porting means each including rigidmeans thereon extending through the rules of the group frictionally heldtherein between the base and working edges of the rules of such groupfor transmitting said pressure across each of said rule supporting meansindependently of the rules of said groups whereby said rules may bewithdrawn from said rule supporting means for replacement thereof whilesaid rule supporting means are frictionally held in said chase bypressure from said chase, separate blank forming rules between said rulesupporting means spacing and separating said rule supporting means fromeach other thereby enabling removal of any of said rule supporting meansincluding the group of rules held therein from the others of said rulesupporting means free from direct frictional engagement with the rulesupporting means adjacent thereto, said separate blank forming rulesbeing frictionally held between said rule supporting means by pressurefrom said chase upon the latter being actuated to lock said rulesupporting means in said chase, and other blank forming rules betweensaid chase and said rule supporting means frictionally held by pressurefrom said chase against the rule supporting means that are next to saidchase upon said chase being actuated to hold said rule supporting meansin said chase.

3. A die for forming a plurality of blanks from sheet 7 materialcomprising: a plurality of separate corresponding groups of blankforming rules each group having working edges for engaging such sheetmaterial and coplanar base edges opposite to said working edges forengagement with a common bed, separate rigid, unitary rule holding meansfrictionally but releasably holding the rules in each group together forremoval of each group as a unit, and a rectangular chase having foursides enclosing said rule supporting means actuatable for transmittingpressure along lines at right angles to each other and to the sides ofsaid chase across the latter to said rule supporting means forfrictionally locking them within said chase, said rule supporting meanseach including rigid means thereon for transmitting said pressure acrosseach of said rule supporting means independently of the rules of thegroup frictionally held therein whereby any of the said rules of eachgroup may be withdrawn from any of said rule supporting means forreplacement thereof while said rule supporting means are locked in saidchase, said rule supporting means being rigid rectangular slabs ofplastic material formed with slots therein, and the rules of said groupsbeing disposed within said slots in frictional engagement with the sidesthereof with their said working edges and said base edges projectingfrom opposite sides of said slabs, said rigid means on said supportingmeans respectively, being wholly within each slab of plastic materialand said rigid means on the separate rule supporting means being alignedwith each other on lines extending across said chase perpendicular tothe sides of said chase.

4. A die for forming a plurality of blanks from sheet materialcomprising: a plurality of separate corresponding groups of blankforming rules each group having working edges for engaging such sheetmaterial and coplanar base edges opposite to said working edges forengagement against a common bed, separate rigid, unitary rule holdingmeans frictionally but releasably holding the rules in each grouptogether for removal of each group as a unit, and a rectangular chasehaving four sides enclosing said rule supporting means actuatable fortransmitting pressure along lines at right angles to each other and tothe sides of said chase across the latter to said rule supporting meansfor frictionally locking them within said chase, said rule supportingmeans each including rigid means thereon for transmitting said pressureacross each of said rule supporting means independently of the rules ofthe group frictionally held therein whereby any of the said rules ofeach group may be withdrawn from any of said rule supporting means forreplacement thereof while said rule supporting means are locked in saidchase, separate blank forming rules between said rule supporting meansspacing and separating said rule supporting means from each otherthereby enabling removal of any of said rule supporting means includingthe group of rules held therein from the others of said rule supportingmeans free from engagement with the rule supporting means adjacentthereto, said blank forming rules being, frictionally held between saidrule supporting means by pressure from said chase upon the latter beingactuated to lock said rule supporting means in said chase, and otherblank forming rules between said chase and said rule supporting meansfrictionally held by pressure from said chase upon said chase beingactuated to lock said rule supporting means in said chase, said rigidmeans being tie elements extending across said recesses and said rulesbeing formed with slots opening outwardly of said base edges of saidrules through which last mentioned slots said elements extend, saidrigid means on said supporting means respectively, being wholly withineach slab of plastic material and said rigid means on the separate rulesupporting means being aligned with each other on lines extending acrosssaid chase perpendicular to the sides of said chase, said rigid meansrespectively being wholly disposed within each of said rule supportingmeans and the said rigid means within the rule supporting means enclosedby said chase being aligned with each other along lines extendingperpendicular to said sides of said chase.

5. The method of fabricating a multiple blank forming die that includesthe steps of: frictionally holding a plurality of blank cutting rulestogether between a plurality of separate rule carrying supports bypressure applied against said supports toward said cutting rules,frictionally holding corresponding separate groups of blank formingrules in said supports, respectively, at a substantially uniform degreeof frictional resistance against removal of the rules in said groupsfrom said supports, independently of said pressure, whereby the rules ofeach of said groups may be separately withdrawn from said supports andreplaced while said supports and said blank cutting rules are heldtogether by said pressure and whereby each of said supports and thegroup of rules frictionally held therein may be removed as a unit fromsaid cutting rules for replacement upon release of said pressure.

References Cited in the file of this patent UNITED STATES PATENTS2,299,191 Toland Oct. 20, 1942

